KZ440 Airbox Fitment help

Hi KZ Riders,

I just got my wifes 83' KZ440 LTD out of storage. I noticed that the previous owner had put some air pod filters on the carbs and apparently discarded the airbox and filter compartment. Since I would bet they didn't rejet the carbs, I bought a used airbox and boots from ebay. I have a pdf of the service manual but I cannot get that air box inside of the frame. I have taken a few pictures in the hope that you can help me out. This is only one of several fixes with the bike but it is the first place I've been stuck. I appreciate your help, thanks!

Remove the battery holder frame first to get more space to install the air box




Michael

Thanks, Sirocco! I will give that a try and let you know.

So, I have been digging into the wife's 83' KZ440 LTD and have some theory questions I was hoping you all could help me with. The airbox that I purchased is now installed but it did not come with an air filter element holder that would normally fit under the tool tray under the seat. I have been trying to determine how best to filter/control the air entering the box and carbs. I have seen people build their own airboxes using a few different pod filter configurations.

I have the two pod style filters as well as two sheets of coarse and fine UNI filter foam but I wanted to see what you thoughts would be on how best to filter the air coming into the airbox and how much space I would need around the filter element. I have purchased a small project box that fits well against the opening to the airbox on the inlet side but it is only about an inch deep. I could attach the pods to the exterior lid of the project box perhaps? Anyhow, any help is appreciated. Thanks!

Just fasten a piece of your sheet foam to the openings.
You will have to experiment with thickness and density of the foam.
This is basically what the factory done. They used foam inside the
triangular housing mounted to the back of the air box.


.

Thanks for the reply. Yeah, that is more or less what I intend to do. I guess my question was inspired more by not knowing if the space around the filter or the inlet opening was something that needed to be precise. I would assume, at my own risk, that the size of the air box does more to regulate the airflow into the carbs than the filter itself.